U.S. patent number 5,791,261 [Application Number 08/735,802] was granted by the patent office on 1998-08-11 for modular pallet system.
This patent grant is currently assigned to Plastic Pallet Production, Inc.. Invention is credited to Robert V. Daigle, Michael John.
United States Patent |
5,791,261 |
John , et al. |
August 11, 1998 |
Modular pallet system
Abstract
A modular pallet system definable in terms of xyz Cartesian
coordinates includes a base structure in a lower xy plane having a
x- and y-linear axis members internestable with each other at
regions of orthogonal intersection to form a rectilinear matrix,
each region of intersection of each linear member including an
aperture of like geometry to each other aperture. The pallet system
further includes a lower snap-lock elements, equal in number to
that of the regions of orthogonal intersection, the snap elements
proportioned for complemental securement within each of the
apertures within each of the regions of orthogonal intersection of
the x- and y-axis members with each other, each of the lower
snap-lock elements including integrally projecting positive z-axis
locking prongs. The system also includes a plurality of z-axis
separators, equal in number to that of the regions of intersection
within the lower xy plane, each of the separators proportioned, in
all xy planes, for enclosure of the z-axis locking prongs of the
lower snap-lock elements, the separators further including four
integral z-axis sides, and open xy planes at upper and lower faces.
The separators operate to define a rigid z-axis dimension of the
pallet system.
Inventors: |
John; Michael (Boca Raton,
FL), Daigle; Robert V. (Deerfield Beach, FL) |
Assignee: |
Plastic Pallet Production, Inc.
(Dallas, TX)
|
Family
ID: |
46203004 |
Appl.
No.: |
08/735,802 |
Filed: |
October 21, 1996 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
523639 |
Sep 5, 1995 |
|
|
|
|
562507 |
Nov 24, 1995 |
|
|
|
|
Current U.S.
Class: |
108/56.3;
108/902; 108/57.33 |
Current CPC
Class: |
B65D
19/0018 (20130101); B65D 19/0075 (20130101); B65D
19/0069 (20130101); B65D 19/0022 (20130101); B65D
2519/00572 (20130101); Y10S 108/902 (20130101); B65D
2519/00104 (20130101); B65D 2519/0083 (20130101); B65D
2519/00373 (20130101); B65D 2519/00034 (20130101); B65D
2519/00069 (20130101); B65D 2519/0094 (20130101); B65D
2519/00567 (20130101); B65D 2519/00835 (20130101); B65D
2519/00288 (20130101); B65D 2519/00318 (20130101); B65D
2519/0084 (20130101); B65D 2519/00557 (20130101); B65D
2519/00333 (20130101); B65D 2519/00756 (20130101); B65D
2519/00308 (20130101) |
Current International
Class: |
B65D
19/00 (20060101); B65D 019/32 () |
Field of
Search: |
;108/56.1,56.3,51.11,902,901,57.25,57.26,57.27,57.31,57.33 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Cuomo; Peter M.
Assistant Examiner: Wilkens; Janet M.
Parent Case Text
REFERENCE TO RELATED APPLICATION
This case is a continuation-in-part of application Ser. Nos.
08/539,639 and 08/562,507, filed Sep. 5, 1995 and Nov. 24, 1995,
respectively.
Claims
Having thus described our invention what we claim as new, useful
and non-obvious and, accordingly, secure by Letters Patent of the
United States is:
1. A modular pallet system definable in terms of xyz Cartesian
coordinates, the system comprising:
(a) a base structure in a lower xy plane, said structure comprising
a plurality of x- and y-linear axis members, said members
internestable with each other at regions of orthogonal intersection
therebetween to form a rectilinear matrix, each of said x-axis
members identical to each other, and each of said y-axis members
identical to each other, and each region of intersection of each
linear member including an aperture, of like geometry to each other
aperture therein;
(b) a plurality of lower snap-lock elements, equal in number to
that of said regions of orthogonal intersection, said lower
elements proportioned for complemental securement within each of
said apertures within each of said regions of orthogonal
intersection of said x- and y-axis members with each other, each of
said lower snap-lock elements including integrally projecting
positive z-axis locking means;
(c) a plurality of z-axis separation means, equal in number to that
of said regions of intersection within said lower xy plane, each of
said separation means proportioned, in all xy planes thereof, for
enclosure of said z-axis locking means of said lower snap-lock
elements, said separation means further including four integral
z-axis sides and open xy planes at upper and lower faces thereof,
said separation means operating to define a rigid z-axis dimension
of the pallet system;
(d) a top structure in an upper xy plane, above said lower xy
plane, said top structure including a plurality of apertures
therein located at z-axis positions corresponding to each of said
region of orthogonal intersection of said x- and y-axis members of
said base structure; and
(e) a plurality of upper snap-lock elements, equal in number to
that of said regions of orthogonal intersection, said upper
snap-lock elements proportioned for complemental securement within
each of said apertures of said top structure, each of said top
snap-lock elements including integrally projecting negative z-axis
locking means proportioned for complemental engages with said
positive z-axis locking means of said lower snap-lock elements,
whereby when said respective pluralities of snap-lock elements are
secured within the respective apertures of said base and top
structures, and said z-axis locking means of said respective
snap-lock elements are secured to each other within said separation
means, there is defined a rigid three-dimensional rectilinear
pallet system.
2. The system as recited in claim 1, in which said top structure
comprises:
four interlockable quadrants within said upper xy plane.
3. The system as recited in claim 2, in which each of said
quadrants include honeycomb-like surfaces thereof.
4. The system as recited in claim 1, in which said locking means of
each of said upper and lower snap-like elements comprises:
mutually complementally prong-like means.
5. The system as recited in claim 4, in which each of said upper
and lower snap-lock elements include:
an xy surface from which said z-axis snap-lock means depend.
6. The system as recited in claim 5 in which said lower and upper
xy planes of the pallet system define a dimension therebetween
sufficient to permit insertion of arms of a fork lift vehicle and a
pallet jack from any side thereof.
7. The system as recited in claim 6, in which said separation means
comprise:
various geometries in xy planes thereof at selectable regions of
intersection of said top and base structures of the pallet
system.
8. The system as recited in claim 6, further comprising:
anti-skid means affixed to selectable areas of said xy plane of
said top structure of the pallet system.
9. The system as recited in claim 4, in which said regions of
intersection of said base structure comprise:
at least four corners, a center, two x-axis non-centers, and two
y-axis non-centers of said base structure.
Description
BACKGROUND OF THE INVENTION
Pallets are flat, typically two-layered rigid articles employed in
the transportation and storage of a vast variety of consumer and
industrial products and materials. Pallets are typically attached
to cartons or packaging of the product or supply of interest at the
site of production or origination of a partially or fully
manufactured product. The pallet assures that the product will be
shipped and stored in a physical relationship to the pallet that is
generally defined by the manufacturer thereof. Further, movement of
products and materials associated with a given pallet can be
effected through the use of the prongs of a forklift vehicle or
pallet jack to facilitate the movement on and off of transportation
vehicle means and for repositioning of pallets and their associated
materials within warehouses. Accordingly, it is to be appreciated
that pallets have, in the present industrial period, become the
predominant manner in which a majority of the industrial output of
the world is transported from a point of manufacture, onto
transportation means, and finally into and within warehousing
facilities, and therefrom to the end user or retailing
establishment.
The norm in pallet construction has been that of wood planks and
beams, connected by nails or screws. The problems of such prior art
pallets have been many, these including without limitation
that:
1. The weight of a commercial wooden pallet is excessive, thereby
giving rise to problems of cost and risk of injury.
2. Wooden pallets cannot be modularized.
3. Projecting nails, and screws and splinters present a safety
problem.
4. The life of wood in typical pallet use is quite limited.
5. Damaged wooden pallets are difficult to repair.
6. Wooden pallets are not easily disposed of.
7. Such pallets cannot be readily recycled, this due primarily to
the presence of nails and screws embedded within the wood structure
thereof.
8. Due to susceptibility of wood to infestation, many countries
require costly fumigation of all wood pallet-containing
imports.
Notwithstanding the relatively nominal cost (about $4.00 to $40.00)
of various wooden pallets, the above problems have given rise to a
need in the art for a modular pallet, that is, one in which the
parts thereof may be readily replaced when damaged, for a pallet
having a considerable longer life and resistance to hostile
environments than the traditional wood pallet, and for one that can
be completely recycled in response to environmental concerns.
The prior art, as known to the inventors, is best represented by
U.S. Pat. No. 5,197,395 (1993) to Pigott and U.S. Pat. No.
5,483,899 (1996) to Christie.
Pigott does not provide a pallet that can be effectively lifted by
a pallet jack which is considered a necessity for a viable pallet.
Further its configuration makes for hygienical problems as it is
very difficult to clean. Trapped foreign matter makes it no better
than a wood pallet. Further, the top and bottom surfaces of Pigott
comprise a unitary, not a modular, structure, as in the instant
system, subject to load and, therefore, to potential degradation.
Further, the internal locking means of Pigott are, unlike the
present system, subject to load and therefore to potential
degradation.
In Christie, the internal locking means are integral with the
vertical-dimension-defining means of the system. This structure
suffers from many functional deficiencies, and its construction
requires a precision which is unobtainable with recycled materials.
Again, hygienics are all but impossible with the closed
compartments which trap foreign matter. Also, the structure of
Christie cannot be lifted from all directions by a fork lift or
pallet jack.
SUMMARY OF THE INVENTION
The present modular pallet system is definable in terms of xyz
Cartesian coordinates. The system more particularly includes a base
structure in a lower xy plane, said structure comprising a
plurality of x- and y-linear axis members, said members
internestable with each other at regions of orthogonal intersection
therebetween to form a rectilinear matrix, each of said x-axis
members identical to each other, each of said y-axis members
identical to each other, and each region of intersection of each
linear member including an aperture, of like geometry to each other
aperture therein. The pallet system further includes a plurality of
lower snap-lock elements, equal in number to that of said regions
of orthogonal intersection, said lower elements proportioned for
complemental securement within each of said apertures within each
of said regions of orthogonal intersection of said x- and y-axis
members with each other, each of said lower snap-lock elements
including integrally projecting positive z-axis locking means. The
system also includes a plurality of z-axis separation means, equal
in number to that of said regions of intersection within said lower
xy plane, each of said separation means proportioned, in all xy
planes thereof, for enclosure of said z-axis locking means of said
lower snap-lock elements, said separation means further including
four integral z-axis sides, and open xy planes at upper and lower
faces thereof, said separation means operating to define a rigid
z-axis dimension of the pallet system. Also included in the system
is a top structure in an upper xy plane, above said lower xy plane,
said top structure including a plurality of apertures therein
located at z-axis positions corresponding to each of said regions
of orthogonal intersection of said x- and y-axis members of said
base structure. There is provided a plurality of upper snap-lock
elements, equal in number to that of said regions of orthogonal
intersection, said upper snap-lock elements proportioned for
complemental securement within each of said apertures of said top
structure, each of said top snap-lock elements including integrally
projecting negative zaxis locking means proportioned for
complemental engagement with said positive z-axis locking means of
said lower snap-lock elements. When said respective lower and upper
snap-lock elements are secured within the respective apertures of
said base and top structures, and said z-axis locking means of said
respective snap-lock elements are secured to each other within said
separation means, thereby defining a rigid three-dimensional
rectilinear pallet system.
It is accordingly an object of the present invention to provide a
modular pallet system having enhanced cost-effectiveness of usage
relative to prior art non-modular and wooden pallets.
It is another object to provide a pallet system which may be
readily repaired by replacing only damaged portions thereof. It is
a further object of the invention to provide a pallet system having
enhanced durability over prior art pallets.
It is a still further object to provide a pallet system that can be
shipped in component parts and then assembled at a destination
without need for tools or special hardware.
It is a still further object to provide a pallet within weight
limitations imposed by insurance companies.
It is a still further object of the invention to provide a pallet
system which, after its life cycle, may be completely recycled.
It is another object to provide a pallet system which will not pose
safety problems associated with the use of sharp metal articles,
such as bolts, screws, and rivets embedded within wooden and
non-modular pallet structures.
The above and yet other objects and advantages of the present
invention will become apparent from the hereinafter set forth Brief
Description of the Drawings, Detailed Description of the Invention
and Claims appended herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the inventive pallet system.
FIG. 2 is a side yz plane view thereof.
FIG. 3 is a side xz plane view thereof.
FIG. 4 is a top plan view of the x-axis member.
FIG. 5 is a side plan view thereof.
FIG. 6 in a bottom plan view thereof.
FIG. 7 is a top plan view of the y-axis member.
FIG. 8 is a side plan view thereof.
FIG. 9 is a bottom plan view thereof.
FIG. 10 is bottom view of the pallet system.
FIGS. 11 to 14 are bottom, top, side and axial cross-sectional
views of the lower snap-lock element.
FIG. 15 is a top view of the first z-axis separation means.
FIG. 16 is a top view of the second z-axis separation means.
FIG. 17 is a top view of the pallet system.
FIG. 18 is an enlarged view of one quadrant of the top structure of
the system.
FIGS. 19-22 are top, bottom, side and axial cross-sectional views
of the upper snaplock element.
FIG. 23 is an assembly view of all parts of the system which occupy
each region of orthogonal intersection of the system.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the perspective view of FIG. 1, the inventive
modular pallet system may be seen to be definable in terms of xyz
cartesian coordinates, in accordance with the protocol shown to the
lower right of said FIG. 1. More particularly, the present pallet
system includes a base structure 10 which exists in a lower xy
plane, a plurality of z-axis separation means 12, and a top
structure 16 which exists in an upper xy plane of the system. The
top structure includes logo or graphic symbol surface 17.
As may be noted, the separation means 12 may be provided in a
variety of geometries such as the geometry of second separation
means 18 which is shown at the corners of the system in FIG. 1.
The system of FIG. 1 may be seen from the yz plane in the view of
FIG. 2, and from the xz plane in the view of FIG. 3.
With more particular reference to the form of the base structure
10, there are, in the views of FIGS. 4, 5 and 6, shown top, side
and bottom plan views of an x-axis linear member 20, three of which
comprise a part of the base structure 10 of the system (see FIG.
10). As may be noted, each x-axis member is provided with xz plane
apertures 22, 24 and 26, each having like geometry to each other.
As may be further noted in the side view of FIG. 5, the region
surrounding each aperture is elevated. As may be noted in the
bottom view of FIG. 6, lower surface 28 of each x-axis member 20 is
provided with a friction enhancing type of surface.
With reference to the views of FIGS. 7, 8 and 9, there is shown in
top, side and bottom plan views respectively a y-axis member 30,
three of which are used in the present modular pallet system. (See
FIG. 10) As may be noted, each y-axis linear member is provided
with apertures 32, 34 and 36 having a geometry identical to said
apertures 22, 24 and 26 of the x-axis members 20. As may be noted
in FIG. 10, the y-axis members 30 are positioned orthonormally to
the x-axis members 20 and are internested therewith. Such
internesting occurs when the x-axis member, which are the lowermost
elements of the system, are placed underneath and within elevated
areas 38 (see FIG. 8) of the y-axis linear members which, thereby,
are placed over the x-axis members 20. The resulting structure of
such internesting may be seen with reference to the bottom view of
FIG. 10 in which may be more particularly seen regions of
intersection 40 which are defined by the internesting of the
apertures 32, 34 and 36 of the y-axis members 30 with the apertures
22, 24 and 26 of the x-axis members 20. It is to be understood that
while the present embodiment shows a structure having three
apertures along each of the x and y axis, within the scope of the
present invention, systems having a smaller or larger number of
regions of orthogonal intersection may be construed.
Following the internesting of the x and y axis linear members, a
plurality of lower snap-lock elements 42 (see FIGS. 11 through 14)
are provided which are equal in number to the number of regions of
orthogonal intersection 40, discussed above. Said lower snap-lock
elements 42 are proportioned for complemental securement within
each of said apertures 24 and 34, said apertures 22 and 32, and
said aperture 26 and 36, of the x and y axis linear members. As may
be noted in the side view of FIG. 13 and the cross-sectional view
of FIG. 14, each lower snap-lock element 42 is provided with a
plurality of positive z-axis locking means 44 which are in the
nature of prong-like means 46. Further, each of the positive z-axis
locking means 44 project from an integral xy axis base 48.
The bottom view of FIG. 11 and the top view of FIG. 12 show but one
of the many xy plane geometries which the present lower snap-lock
elements 42 may take.
The possible structure of the separation means 12 and 18 are shown
with reference to the xy plane view of FIG. 15 and 16 respectively.
Therein may be seen but two of the possible xy plane geometries of
the z-axis separators that may be employed at the corners, the
center, the x-axis non-centers and the y-axis non-centers of the
present system. As may be appreciated, the larger (in the x-axis)
separation means 18 will be more generally used at the corners of
the structure to provide enhanced strength at such locations. It is
to be further noted that separation means 12 and 18 provide the
z-axis clearance between the base and top structures 10 and 16
necessary to accommodate the arms of a fork lift and pallet
jack.
In FIG. 17 is shown the present modular pallet system in top plan
view. Therein, as may be seen, top structure 16 may be formed of
quadrants of honeycomb-like structure 50, one of which is
particularly shown in FIG. 18. Each quadrant is provided with first
interlock means 52 along the x-axis thereof and second interlock
means 54 along the y-axis thereof. As may be appreciated, assembly
of the top structure is affected by connecting the x-axis interlock
means 52 to each other and then connecting the y-axis means 54 to
each other. The resultant structure is one in which there exists a
plurality of apertures 56 located at the same z-axis positions
which corresponds to said regions of orthogonal intersection 40 of
said x and y axis linear members of the base structure 10 of the
system. Accordingly, apertures 56 of the top structure are aligned
directly over the apertures 40 of the base structure. Within said
apertures 56 are placed a plurality of upper snap-lock elements 58
(see FIGS. 17 and FIGS. 19 to 22) which are equal in number to that
of the regions of orthogonal intersection and, thereby, are equal
in number to the number of said lower snap-lock elements 42. Each
of said upper snap-lock elements are proportioned for complemental
securement within each of said apertures 56 of the top structure
16. As may be more particularly seen in the views of FIGS. 19 to
22, each of said upper snap-lock elements 58 include an integral xy
plane base 60 and a plurality of negative z-axis locking means 62
having prong-like means 64 at the ends thereof. Locking means 62
and prong means 64 are proportioned for complemental engagement
with the positive z-axis locking means 44 and associated prongs 56
of lower snap-lock elements 42.
In the assembly detail view of FIG. 23, a view which is correct in
both the xz and yz planes, may be seen the interlock between the
upper and lower snap-lock elements 42 and 58 respectively and, as
well, the inter-relationship between separation means 12 and 18,
and base structure 10 (formed of the combination of x and y linear
elements 20 and 30 respectively) and upper structure 16 and its
constituent honeycomb quadrants 50. More particularly, the z-axis
defining function of the separation means may be seen as that of
enabling the three-dimensional rigid structure of the present
modular pallet system.
While there has been shown and described the preferred embodiment
of the instant invention it is to be appreciated that the invention
may be embodied otherwise than is herein specifically shown and
described and that, within said embodiment, certain changes may be
made in the form and arrangement of the parts without departing
from the underlying ideas or principles of this invention as set
forth in the Claims appended herewith.
* * * * *